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Northrop Grumman Tests NASA BOLE Rocket Booster in Utah

Northrop Grumman’s BOLE booster achieves 4M lbs thrust in Utah test, advancing Artemis missions with composite tech despite nozzle anomaly.

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Northrop Grumman’s BOLE Solid Rocket Booster: Pushing the Limits of Space Propulsion

On June 26, 2025, Northrop Grumman conducted a full-scale static fire test of NASA’s Booster Obsolescence and Life Extension (BOLE) solid rocket booster in Promontory, Utah. This test marked a major milestone in the evolution of solid rocket propulsion, showcasing the most powerful segmented solid rocket motor ever built for human spaceflight. Producing over 4 million pounds of thrust, the 156-foot booster is a critical component in advancing NASA’s Artemis program and future deep-space missions.

BOLE represents a significant evolution from the Space Launch System (SLS) boosters, integrating a carbon-fiber composite case, updated propellant formulation, and advanced control systems. These innovations aim to enhance performance, reduce weight, and address the obsolescence of legacy components. While the test encountered an anomaly near the end of the burn, the data collected is expected to refine future designs and improve reliability for upcoming Artemis missions.

This article explores the technical advancements, test outcomes, economic context, and strategic implications of the BOLE booster, offering a comprehensive look at its role in shaping the future of human space exploration.

Technical Innovations and Performance Enhancements

Composite Case and Structural Improvements

One of the most notable changes in the BOLE booster is the transition from a steel casing to a carbon-fiber composite structure. This shift reduces the overall weight by approximately 15%, allowing for better thrust-to-weight ratios and increased payload capacity. The new casing, developed using sand-mandrel technology, offers enhanced structural integrity under high-pressure conditions and streamlines manufacturing through automation.

By leveraging composite materials, Northrop Grumman aligns BOLE with commercial aerospace standards, promoting interoperability across government and private-sector programs. The integration of U.S.-sourced metallic components also strengthens domestic supply chains, reducing reliance on obsolete parts and foreign suppliers.

These structural innovations not only improve performance but also support long-term sustainability in booster production. The lighter, more resilient casing is crucial for supporting missions that demand high payload capacities, such as lunar habitat modules or Mars-bound cargo.

“The carbon fiber composite case enables better booster performance, faster manufacturing, and aligns with commercial standards by providing commonality among our infrastructure, supply chain, and manufacturing operations.” — Northrop Grumman

Propellant and Thrust Vector Control Systems

BOLE’s updated propellant formulation includes a high-energy mix of ammonium perchlorate, aluminum powder, and PBAN (polybutadiene acrylonitrile) binder. This composition increases energy density by about 12% compared to the SLS Block 1 boosters, allowing for more efficient combustion and higher thrust output.

Complementing the propellant upgrades is the introduction of an electronic thrust vector control (eTVC) system. Unlike traditional hydraulic actuators, the eTVC uses electromechanical drives to adjust the nozzle direction with millisecond precision. This system enhances flight stability and trajectory control, especially during critical phases such as liftoff and stage separation.

These propulsion and control advancements are derived from Northrop Grumman’s previous work on the OmegA rocket and other defense systems, emphasizing the cross-application of proven technologies. As a result, BOLE represents a fusion of legacy reliability and cutting-edge innovation.

Test Results and Anomaly Overview

The June 2025 test, designated Development Motor 1 (DM-1), aimed to validate BOLE’s integrated systems under full-scale conditions. Over 700 data channels monitored thermal, structural, and combustion parameters during the two-minute burn. Initial results were promising: the booster achieved over 4 million pounds of thrust and maintained structural integrity for most of the test duration.

However, at around 110 seconds into the burn, an anomaly occurred involving the nozzle’s carbon-carbon throat insert. High-speed footage showed debris ejecting from the nozzle, followed by asymmetric flame patterns. The nozzle eventually disintegrated, though the motor continued firing until shutdown at 140 seconds.

Post-test analysis attributed the failure to thermal erosion triggered by localized propellant segregation. Despite the anomaly, 92% of test objectives were achieved, including successful validation of the composite casing and eTVC system. The incident provides critical data for refining nozzle design and improving propellant casting processes.

“While the motor appeared to perform well through the most harsh environments of the test, we observed an anomaly near the end… This test provides us with valuable data to iterate our design for future developments.” — Jim Kalberer, VP, Propulsion Systems, Northrop Grumman

Strategic and Economic Implications

Program Funding and Lifecycle Costs

BOLE development is funded through NASA’s $3.19 billion Booster Production and Operations Contract (BPOC) awarded in 2021. This contract supports booster production for Artemis IV-VIII and the development of BOLE for Artemis IX and beyond. Each BOLE unit is estimated to cost around $336 million, a notable reduction from the $470 million cost of earlier SLS boosters.

The cost savings are attributed to supply chain consolidation, automated manufacturing, and design standardization. However, challenges remain. NASA’s Office of Inspector General has reported cost overruns in RS-25 engine production, which may offset some of the savings from BOLE.

Overall, the BOLE program is projected to cost $4.8 billion through 2035, including design iterations and anomaly resolution. These investments reflect NASA’s commitment to maintaining a domestic solid motor industrial base and supporting high-performance launch capabilities for deep space missions.

Integration with Artemis Program

BOLE’s operational debut is scheduled for Artemis IX, tentatively planned for 2033. Earlier Artemis missions will continue using legacy five-segment boosters derived from the Space Shuttle program. The transition to BOLE is contingent on resolving the nozzle anomaly and completing additional tests by 2027.

Each BOLE booster adds approximately five metric tons of payload capacity to lunar orbit, a critical enhancement for assembling infrastructure like the Lunar Gateway. However, delays in BOLE readiness could impact the Artemis schedule, potentially affecting timelines for Mars mission preparations.

NASA officials acknowledge the complexity of aligning booster development with mission cadence. The program must balance technical progress with budgetary constraints and evolving policy priorities, especially amid discussions about scaling back the SLS program after Artemis III.

Global Context and Competitive Landscape

BOLE enters a competitive global market for heavy-lift propulsion. Europe’s P120C solid booster, used in Ariane 6, and India’s S200 booster for LVM3 offer alternative approaches with varying cost and performance trade-offs. While BOLE leads in segmented motor thrust, its high cost per kilogram to orbit, estimated at $5,000, limits its commercial viability compared to reusable systems like SpaceX’s Falcon Heavy.

Nonetheless, BOLE’s technology could be adapted for other applications, such as tactical missiles or planetary cargo missions. Its composite casing and eTVC systems are scalable and may support future hybrid launch architectures combining solid and liquid propulsion.

Strategically, BOLE strengthens the U.S. position in solid propulsion technology, supporting thousands of jobs and preserving industrial capabilities critical to national security and space exploration.

Conclusion

The BOLE booster test marks a significant step in the evolution of solid rocket propulsion. Despite the nozzle anomaly, the test validated key innovations in materials, propellant, and control systems. These advancements promise enhanced payload capacity and improved manufacturing efficiency, supporting NASA’s long-term exploration goals.

Looking ahead, the success of BOLE depends on resolving technical issues, securing sustained funding, and aligning with broader space policy objectives. If fully realized, BOLE could extend the capabilities of the SLS program into the 2040s and facilitate human missions to the Moon, Mars, and beyond.

FAQ

What is the BOLE booster?
BOLE (Booster Obsolescence and Life Extension) is a new solid rocket booster developed by Northrop Grumman for NASA’s Artemis missions. It features a composite casing, updated propellant, and advanced control systems.

How powerful is the BOLE booster?
The BOLE booster produces over 4 million pounds of thrust, making it the most powerful segmented solid rocket motor ever built for human spaceflight.

What caused the anomaly during the June 2025 test?
The anomaly was caused by thermal erosion in the nozzle’s carbon-carbon throat insert, likely due to propellant segregation. Despite this, 92% of test objectives were met.

When will BOLE be used in a mission?
BOLE is expected to debut on Artemis IX, currently scheduled for 2033, pending resolution of the nozzle issue and completion of further testing.

Why is BOLE important for NASA?
BOLE enhances payload capacity, supports U.S. manufacturing, and addresses the obsolescence of legacy components, making it vital for future deep-space missions.

Sources: Northrop Grumman, NASA, NASA Office of Inspector General, European Space Agency, ISRO

Photo Credit: Northrop Grumman

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Space & Satellites

Space Nuclear Power Faces Logistical and Economic Barriers, DRACO Canceled

Experts say space nuclear power challenges are logistical and economic, not technical. DRACO canceled; focus shifts to nuclear reactors in space and on the Moon.

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This article summarizes reporting by Aerospace America.

For decades, the aerospace industry has recognized the immense potential of space nuclear power. Despite possessing the foundational technical knowledge since the 1960s, modern spacecraft continue to rely predominantly on chemical propulsion and solar arrays. A recent workshop at the May 2026 AIAA ASCEND event in Washington, D.C., sought to unpack this enduring paradox.

According to reporting by Aerospace America, a panel of aerospace and policy experts concluded that the primary barriers to deploying nuclear reactors in space are no longer technical. Instead, the industry is grappling with logistical, economic, and systemic hurdles that have repeatedly stalled progress.

The recent cancellation of the highly publicized Demonstration Rocket for Agile Cislunar Operations (DRACO) program in mid-2025 serves as a stark, real-world validation of these expert assessments, demonstrating how shifting economic landscapes can ground even the most ambitious nuclear initiatives.

The Illusion of Technical Barriers

During the ASCEND workshop, hosted by Brian Weeden of The Aerospace Corporation, panelists emphasized the extensive capital and time already invested in space nuclear research. Bhavya Lal, a professor at the RAND School of Public Policy, highlighted that the United States has spent 60 years and over $20 billion proving that the technology itself is viable.

“The technology has never been the bottleneck. What has failed each time is the system around the reactor,” Lal stated, according to the workshop coverage.

Lal further explained that these systemic failures include shifting mission scopes, a lack of political continuity, and unstable leadership architectures that prevent long-term projects from reaching the launch pad.

Stagnation Since the Space Race

The historical context of space nuclear power underscores the panel’s frustrations. During the Cold War, the U.S. heavily researched and successfully ground-tested nuclear thermal rockets through initiatives like the NERVA program. However, as reported by Aerospace America, these programs were ultimately scrapped due to changing political administrations and budget cuts following the Apollo era.

Tabitha Dodson, a program manager at the DARPA Defense Sciences Office, noted the resulting stagnation in the field during her panel remarks.

“The United States hasn’t really evolved our nuclear space technology since the fifties or sixties,” Dodson remarked at the event.

Dodson added that current research priorities have had to pivot toward radioisotope power systems and direct-energy power conversion systems to maintain momentum in a risk-averse funding environment.

Economic Realities and the DRACO Cancellation

The intersection of aerospace engineering and economic viability was brought into sharp focus with the recent fate of the DRACO program. Initiated in 2020 as a joint effort between DARPA, NASA, Lockheed Martin, and BWX Technologies, DRACO aimed to test a nuclear thermal rocket in orbit by 2027. Nuclear thermal propulsion was projected to be two to three times more efficient than chemical propulsion, potentially halving the travel time to Mars.

The Impact of Commercial Launch Costs

In June 2025, DARPA officially canceled the DRACO program. According to public statements from DARPA deputy director Rob McHenry, the decision was driven entirely by economics rather than technical failure.

The rapid decrease in commercial launch costs, largely propelled by the heavy-lift capabilities of companies like SpaceX, fundamentally altered the financial equation. The massive research and development costs required to perfect nuclear thermal propulsion could no longer be justified by a positive return on investment when chemical launches had become so inexpensive.

Current Mandates and the Path Forward

Despite the setbacks in nuclear propulsion, the push for nuclear power generation in space remains robust. Current executive mandates have established ambitious timelines, aiming for a functional nuclear reactor in space by 2028 and a working reactor on the lunar surface by 2030. These systems are considered critical for supporting long-term lunar habitats and deep-space exploration missions.

Balancing Ambition and Safety

Aaron Miles, Coordinator for Strategic Capabilities at the White House Office of Science and Technology Policy, discussed these targets at the ASCEND workshop. He emphasized the administration’s focus on setting goals that push the industry forward without ignoring logistical realities.

“Lunar surface reactor development efforts and in-space reactor efforts can benefit each other,” Miles noted regarding the dual mandates.

To meet these goals while navigating strict regulatory and safety hurdles, modern programs are utilizing High-Assay Low-Enriched Uranium (HALEU). Furthermore, contemporary reactor designs ensure that fission is only initiated once the system is safely in orbit, mitigating the historical public fears and international treaty complications associated with launching nuclear material.

AirPro News analysis

We observe that the pivot from nuclear propulsion (like the canceled DRACO program) to stationary nuclear surface power reflects a pragmatic maturation of the aerospace sector. While reusable chemical rockets have decisively won the current launch economics battle, sustained deep-space habitats and lunar bases will undeniably require the continuous, high-density energy that only nuclear reactors can provide. The looming 2028 and 2030 mandates will serve as a critical test of whether the U.S. government and its commercial partners can finally overcome the systemic inertia and political discontinuity described by the ASCEND panelists.

Frequently Asked Questions

What was the DRACO program?

The Demonstration Rocket for Agile Cislunar Operations (DRACO) was a joint U.S. government and industry program initiated in 2020 to develop and test a nuclear thermal rocket by 2027. It was canceled in June 2025 due to shifting economic priorities and the falling cost of commercial chemical rocket launches.

Why is nuclear power needed in space?

While solar panels and chemical batteries are sufficient for operations near Earth, deep-space exploration and permanent lunar or Martian habitats require reliable, high-density power sources that can operate continuously without sunlight or frequent resupply.

What is HALEU?

High-Assay Low-Enriched Uranium (HALEU) is a type of nuclear fuel that provides a balance between high energy output and safety, making it a preferred choice for modern space reactor designs to comply with international regulations and safety standards.

Sources

Photo Credit: Aerospace America

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SpaceX Secures $4.16B Contract for Space-Based Airborne Targeting

SpaceX awarded $4.16B by U.S. Space Force to develop SB-AMTI satellite constellation for global airborne threat detection by 2028.

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This article summarizes reporting by DefenseScoop.

The U.S. Space Force has awarded SpaceX a $4.16 billion Other Transaction Authority (OTA) agreement to accelerate the development of the Space-Based Airborne Moving Target Indicator (SB-AMTI) program. According to reporting by DefenseScoop, the May 29, 2026, award aims to deploy a constellation of satellites capable of continuously detecting, tracking, and targeting airborne threats, including aircraft, drones, and cruise missiles, globally from space.

This multi-billion dollar contract highlights a strategic shift by the Pentagon to move critical surveillance capabilities from vulnerable airborne platforms to a more resilient space-based architecture. The Space Force expects to field an initial constellation by 2028, providing the Joint Force with an early operational capability.

SpaceX’s selection is part of a broader competitive procurement strategy. According to the source material, the aerospace company is one of nine vendors selected in April 2026 to compete for the SB-AMTI program. The Space Force anticipates issuing multiple awards to other vendors in the coming year to maintain a diverse industrial base.

The Shift from Air to Space

Retiring Legacy Airborne Systems

Historically, the U.S. military has relied on airborne warning and control system (AWACS) aircraft, such as the aging E-3 Sentry and the retired E-8 JSTARS, to execute moving target indicator missions. However, DefenseScoop reports that as adversaries develop increasingly sophisticated anti-access/area-denial (A2/AD) systems, these large, slow-moving aircraft have become highly vulnerable in contested airspace.

To address these operational blind spots, the Space Force is developing SB-AMTI to complement traditional airborne sensing. While the Air Force is currently procuring the E-7 Wedgetail to replace the E-3 Sentry, following congressional intervention to save the E-7 program from budget cuts, the Pentagon’s long-term goal is to transition the bulk of AMTI tasks into the space domain for enhanced survivability.

“To compliment traditional airborne sensing, the requirement for a layered, highly resilient tracking architecture is evident.”

, U.S. Space Force press release

Contract Details and Strategic Context

Funding and the “Golden Dome” Framework

The $4.16 billion OTA agreement tasks SpaceX with building an interconnected “system-of-systems” that combines space-based sensors, secure communication links, and ground processing to track moving airborne targets in real-time. To support this architecture, the Space Force has requested $7 billion to begin the formal procurement of SB-AMTI in fiscal year 2027, though DefenseScoop notes these funds are contingent upon Congress passing a reconciliation bill.

The SB-AMTI program is also a critical component of President Donald Trump’s proposed “Golden Dome” missile defense initiative. This framework aims to create a multi-layered defense system spanning ground, air, and space to detect and intercept airborne threats. The military is fast-tracking the SB-AMTI program to ensure the defensive system can meet its 2028 operational target.

“By focusing these capabilities to the space domain, we are providing the Joint Force with sustained battlespace awareness of contested airspace.”

, Col. Ryan Frazier, Acting Space Force Portfolio Acquisition Executive

SpaceX’s Growing Defense Portfolio

A Week of Multi-Billion Dollar Awards

This latest contract cements SpaceX’s position as a dominant player in U.S. national security. According to the provided research, the SB-AMTI award arrives just days after the Space Force granted SpaceX a separate $2.29 billion contracts on May 26, 2026, for the Space Data Network Backbone program, which will provide satellite communications for future missile interceptors.

In a single week, SpaceX secured nearly $6.45 billion in defense contracts. This surge in government backing coincides with industry reports indicating that SpaceX is preparing for an initial public offering (IPO) that could value the company at over $1.5 trillion.

Future Milestones and Parallel Programs

Looking Toward 2035

The Space Force has outlined an aggressive timeline for its space-based surveillance initiatives. Following the projected 2028 deployment of the initial SB-AMTI satellite constellation, the military anticipates operating second- and third-generation systems by 2035.

In parallel, the Space Force is developing the Space-Based Ground Moving Target Indicator (SB-GMTI) program to track ground-based targets. DefenseScoop reports that this complementary system is currently in the research-and-development phase.

“We will not leverage any one single provider; instead, we are partnering with a highly diversified pool of traditional and non-traditional vendors…”

, Col. Ryan Frazier, Acting Space Force Portfolio Acquisition Executive

AirPro News analysis

At AirPro News, we observe that the rapid succession of multi-billion dollar OTA agreements awarded to SpaceX underscores a fundamental shift in Pentagon procurement. By utilizing Other Transaction Authority agreements, the Space Force is bypassing traditional, often sluggish acquisition processes to field critical capabilities on an accelerated timeline. This is particularly vital given the 2028 target for the “Golden Dome” initiative.

Furthermore, the explicit linkage of the SB-AMTI program to national missile defense suggests that space-based sensing is no longer viewed merely as a support function, but as the primary nervous system for future combat operations. While the Space Force publicly emphasizes vendor diversity, noting that SpaceX is just one of nine companies selected for the vendor pool, the sheer financial volume of SpaceX’s recent awards indicates that the industrial base for national security space is heavily reliant on a few highly capable mega-constellation providers.

Frequently Asked Questions

What is the SB-AMTI program?

The Space-Based Airborne Moving Target Indicator (SB-AMTI) is a U.S. Space Force initiative designed to deploy a constellation of satellites capable of detecting, tracking, and targeting airborne threats globally from space.

How much is the SpaceX contract worth?

The U.S. Space Force awarded SpaceX a $4.16 billion Other Transaction Authority (OTA) agreement for the SB-AMTI program on May 29, 2026.

When will the SB-AMTI system be operational?

The Space Force projects the deployment of an initial SB-AMTI satellite constellation by 2028, with second- and third-generation systems anticipated by 2035.

Sources

Photo Credit: Starbase Texas

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Space & Satellites

NASA X-59 Set for First Supersonic Flight in June 2026

NASA’s X-59 experimental aircraft will make its first supersonic flight in June 2026 to test quiet supersonic technology and reduce sonic booms.

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NASA’s experimental X-59 aircraft is preparing to cross a historic aviation threshold. According to an official press release from the space agency, the quiet supersonic research aircraft is scheduled for its first supersonic flight in early June 2026. This milestone marks a critical phase in NASA’s Quesst (Quiet SuperSonic Technology) mission, which seeks to demonstrate that an aircraft can break the sound barrier without producing a disruptive sonic boom.

Since its maiden flight in October 2025, the X-59 has successfully completed 14 subsonic test flights, according to NASA’s project data. The upcoming tests will transition the aircraft into a rigorous “envelope expansion” phase. By gathering precise acoustic data, NASA ultimately hopes to provide federal and international regulators with the evidence needed to reconsider the 53-year-old ban on commercial supersonic flight over land.

To prepare for these high-stakes flights, the X-59 team has recently accelerated its testing cadence. NASA reports that in late April 2026, the ground crew and flight team successfully executed two test flights in a single day for the first time, demonstrating the aircraft’s growing reliability.

The Quesst Mission and Envelope Expansion

Pushing Toward Mach 1.4

The initial supersonic test scheduled for early June 2026 will see the X-59 cross the sound barrier, exceeding 630 mph, at an altitude of approximately 43,000 feet. Following this initial breakthrough, NASA plans to push the aircraft toward its ultimate “mission conditions.” Official specifications dictate a target cruising speed of Mach 1.4 (approximately 925 mph) at an altitude of 55,000 feet.

In the agency’s press release, Cathy Bahm, Project Manager for NASA’s Low Boom Flight Demonstrator, emphasized the importance of this testing phase:

“What comes next is the first time this one-of-a-kind aircraft will fly supersonic. We are starting toward the mission conditions test point that X-59 was designed for.”

Bahm further noted that completing the first mission-conditions flight is a significant milestone, as it allows the team to verify that the aircraft performs safely in its intended environment.

Engineering a “Quiet Thump”

Unconventional Design and Testing Methodology

The X-59 was built by Lockheed Martin Skunk Works under a $247.5 million contract awarded by NASA in 2018. To achieve its acoustic goals, the aircraft features a highly unconventional design. According to project specifications, the nose accounts for nearly a third of the aircraft’s total length. This elongated structure is engineered specifically to scatter shock waves before they can merge into a loud sonic boom.

Because of this unique aerodynamic shape, the cockpit lacks a forward-facing windshield. Instead, NASA equipped the X-59 with a high-resolution External Vision System (XVS), which feeds live camera footage to an in-cockpit monitor to allow pilots to navigate safely.

NASA test pilot Jim ‘Clue’ Less detailed the cautious approach the flight team is taking during this envelope expansion phase:

“From here on out, once we’re airborne, we can increase speed and increase altitude in small, measured chunks, looking at things as we go and not getting ahead of ourselves.”

During these initial supersonic flights, the public will not yet hear the anticipated “quiet thump.” NASA states that the X-59 will be accompanied by a traditional F-15 chase plane equipped with a specialized shock-sensing probe. The traditional sonic boom produced by the F-15 will obscure the X-59’s quieter acoustic signature from observers on the ground.

AirPro News analysis

We view the upcoming June 2026 flights as a pivotal moment not just for NASA, but for the broader commercial aviation industry. In 1973, the Federal Aviation Administration (FAA) banned commercial supersonic flights over U.S. land due to severe noise pollution. For historical context, the retired Concorde produced a sonic boom of about 105 to 110 Effective Perceived Noise Level in decibels (EPNdB). NASA’s target for the X-59 is a mere 75 EPNdB, roughly equivalent to the sound of a car door closing 20 feet away.

If the current Phase 1 envelope expansion is successful, NASA will move to Phase 2 (Acoustic Validation) later in 2026, utilizing a 48-kilometer-long array of 125 sonic boom recorders in the Mojave Desert. Phase 3 will involve flying the aircraft over selected U.S. communities to gather public feedback. We believe that this methodical, data-driven approach is the most viable pathway for the aerospace sector to establish new noise standards and potentially unlock a new era of overland commercial supersonic travel.

Frequently Asked Questions (FAQ)

What is the NASA X-59?

The X-59 is an experimental research aircraft developed by NASA and Lockheed Martin as part of the Quesst mission. It is designed to fly faster than the speed of sound without producing a loud sonic boom, reducing the noise to a quiet “thump.”

When is the X-59’s first supersonic flight?

According to NASA, the aircraft is scheduled to make its first supersonic flight in early June 2026, crossing the sound barrier at an altitude of approximately 43,000 feet.

Why does the X-59 have no forward windshield?

To prevent shock waves from merging into a sonic boom, the X-59 requires an exceptionally long, pointed nose, which obstructs forward visibility. Pilots use an External Vision System (XVS), a network of cameras and screens, to see directly in front of the aircraft.

Sources

Photo Credit: NASA

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